2005 Champion CHALLENGER: complaints, problems and recalls

Reported: 2005-04-29 (April 29, 2005)

ON CERTAIN DIESEL BUSES BUILT ON FORD E-SERIES CHASSIS AND EQUIPPED WITH CARRIER VACUUM PUMP BRACKETS, THE BRACKETS COULD BREAK.

Consequence: WHEN THE BRACKET BREAKS, THE VACUUM PUMP THAT PROVIDES THE POWER TO THE POWER BRAKES BECOMES INOPERATIVE, INCREASING THE RISK OF A CRASH. ALSO, THE POWER STEERING COULD BE AFFECTED IF THE BELT GETS CAUGHT IN THE OTHER BELTS.

Remedy: CARRIER IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. OWNERS MAY CONTACT CARRIER SERVICE DEPARTMENT AT 1-800-450-2211.

Reported: 2006-04-24 (April 24, 2006)

ON CERTAIN TRANSIT BUSES EQUIPPED WITH RICON S AND K SERIES PLATFORM STYLE WHEELCHAIR LIFTS, THE VERTICAL SUPPORT ARMS FOR THE LIFTS WERE IMPROPERLY WELDED ALLOWING THE LIFT TO STOW IMPROPERLY.

Consequence: IN THE EVENT THIS CONDITION OCCURS DURING PASSENGER OPERATIONS IT MAY NOT BE POSSIBLE TO CLOSE THE LIFT DOOR CAUSING THE VEHICLE INTERLOCKS TO REMAIN ENGAGED PREVENTING MOVEMENT OF THE VEHICLE OR THE ABILITY TO LOAD OR UNLOAD PASSENGERS WITH DISABILITIES FROM THE VEHICLE.

Remedy: CHAMPION IS WORKING WITH RICON TO REMEDY THESE BUSES. THE TWO LIFT ARMS WILL BE REPLACED FREE OF CHARGE. OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR CHAMPION AT 1-810-724-6474.

Reported: 2006-09-20 (September 20, 2006)

ON CERTAIN TRANSIT BUSES BUILT ON WORKHORSE CHASSIS AND EQUIPPED WITH GM 8.1L V8 ENGINES, IMPROPER HARDENING DURING THE HEAT TREATMENT PROCESS CAN CAUSE THE FUEL RAIL PULSE DAMPER RETAINER CLIP TO FRACTURE, RESULTING IN INADEQUATE RETENTION OF THE DAMPER. IF THE DAMPER BECOMES LOOSE, FUEL COULD BE PUMPED BY THE FUEL PUMP INTO THE UNDER HOOD AREA.

Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD RESULT.

Remedy: CHEVROLET AND WORKHORSE ARE HANDLING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN (PLEASE SEE 06V225 AND 06V289). DEALERS WILL REPLACE THE FUEL RAIL PULSE DAMPER RETAINER CLIPS ON THESE ENGINES FREE OF CHARGE. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, WORKHORSE AT 877-294-6773 OR THOR INDUSTRIES AT 937-596-6849.

Reported: 2007-12-14 (December 14, 2007)

CHAMPION BUS IS RECALLING 375 MY 2005-2007 CHAMPION, CHALLENGER, CRUSADER, CTS, DEFENDER AND GENERAL COACH MODEL CORPORAL AND M1235 BUSES EQUIPPED WITH BRAUN PLATFORM LIFTS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." A PASSENGER CAN APPROACH THE EXPOSED LIFT DOORWAY WITHOUT THE AUDIBLE ALARM ALERTING THEM OF THEIR PROXIMITY TO THE THRESHOLD.

Consequence: SHOULD THE THRESHOLD WARNING SYSTEM FAIL TO OPERATE, THE LIFT USER CAN FALL FROM THE VEHICLE AND BE SERIOUSLY INJURED.

Remedy: CHAMPION IS WORKING WITH BRAUN CORPORATION TO HAVE THE DOORWAY LIFT FIXED FREE OF CHARGE (PLEASE SEE 06E094). OWNERS MAY CONTACT CHAMPION AT 1-800-331-5761 OR BRAUN CORPORATION AT 1-800-946-7513.

Reported: 2008-04-24 (April 24, 2008)

CHAMPION BUS IS RECALLING 503 MY 2005-2008 DEFENDER, CHALLENGER, CTS-RE, CTS-FE AND CRUSADER BUSES EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE BUSES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.

Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy: CHAMPION BUS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR CHAMPION BUS AT 1-937-596-6849.

Reported: 2008-09-25 (September 25, 2008)

CHAMPION BUS IS RECALLING 503 MY 2005-2007 CHALLENGER, CRUSADER, DEFENDER, MY 2005-2006 CORPORAL, MY 2006 CTS-RE, AND MY 2007 CTS-FE AND IC DEFENDER TRANSIT BUSES EQUIPPED WITH A RICON PLATFORM STYLE WHEELCHAIR LIFT. THIS LIFT FAILS TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEMS FOR MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.

Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.

Remedy: CHAMPION BUS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFT FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR CHAMPION BUS AT 1-800-331-5761.

Reported: 2009-09-24 (September 24, 2009)

CHAMPION BUS IS RECALLING CERTAIN MODEL YEAR 2003 THROUGH 2010 TRANSIT BUSES MANUFACTURED BETWEEN JANUARY 2003 AND AUGUST 2009 EQUIPPED WITH LUMINATOR HORIZON LED SIDE DESTINATION SIGNS. THE CONNECTOR BOARD CAN CORRODE DUE TO AN ACCUMULATION OF MOISTURE UNDER THE CONNECTOR.

Consequence: A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.

Remedy: CHAMPION BUS WILL NOTIFY OWNERS AND LUMINATOR WILL REPAIR THE BUSES FREE OF CHARGE. PLEASE SEE LUMINATOR'S DEFECT REPORT 09E-054. THE SAFETY RECALL BEGAN ON DECEMBER 11, 2009. OWNERS MAY CONTACT LUMINATOR AT 1-972-516-3033 OR CHAMPION BUS AT 1-800-331-5761.

Reported: 2010-11-18 (November 18, 2010)

CHAMPION BUS IS RECALLING CERTAIN BUSES EQUIPPED WITH TRANS AIR TA 73 EVAPORATORS. THE EVAPORATOR UTILIZES A POWER RESISTOR TO REGULATE BLOWER SPEED. SHOULD A SHORT OCCUR IN THE "LOW OR MEDIUM SPEED" CIRCUIT WHILE THE BLOWER IS IN HIGH SPEED, THE SHORT WILL CAUSE THE SUPPLY VOLTAGE TO FEEDBACK THROUGH THE RESISTOR TO GROUND, NOT DRAWING ENOUGH CURRENT TO TRIP THE FUSE.

Consequence: THIS WOULD CAUSE THE RESISTOR TEMPERATURE TO RISE TO A POINT WHERE IT WILL MELT AND POSSIBLY IGNITE THE PLASTIC BLOWER HOUSING TO WHICH IT IS MOUNTED. THE OVERHEATING CAN RESULT IN A FIRE.

Remedy: CHAMPION BUS IN COOPERATION WITH TRANS AIR WILL INSTALL A THERMAL SHUTDOWN DEVICE IN SERIES WITH THE SPEED RESISTORS. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON DECEMBER 6, 2010. OWNERS MAY CONTACT TRANS AIR WARRANTY AND SERVICE CENTER AT 1-800-673-2446.